SEVERE SERVICE CONTROL VALVES

Blakeborough

Weir Valves & Controls The key to the success of Weir Valves & Controls is our capability to deliver engineering solutions that add value to the customers process. We offer a total package of products to meet end-to-end project requirements. Using our own analysis and configuration system, we will design and deliver the optimum valves and controls solution to protect the value of the production process. A rigorous programme of information management means that the division is able to take a more anticipatory role in defining the future needs and expectations of the market by fully utilising the organisation's critical resources to provide whole process isolation and control valve solutions for the global Energy sector. With a comprehensive range of engineered valve products Weir Valves & Controls have developed an extensive global installed base and expertise across a wide range of industry sectors: Power Generation General Industrial Oil & Gas Production Refining Petrochemical Chemical Pulp & Paper Desalination

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Blakeborough

SEVERE SERVICE CONTROL VALVES

Quality assurance Weir Valves & Controls operates quality programmes to cover the full scope of their activities. Comprehensive quality systems have been developed to serve the power, oil and gas and industrial markets which they serve. The company holds approvals to: ASME Section III N, NPT, NV ASME Section I V ASME Section VIII code UV BS EN ISO 9001:1994 NF EN ISO 9001 API Q1 TO API LICENCES API 6D (6D-0182) AND API 6A (6A-0445) API 526 TUV - AD MERKBLATT WRD HP 0

Blakeborough Controls
The Control Valve business unit have designed and manufactured valves for in excess of 50 years. Their control valve product range offers an extensive choice in terms of size, pressure class, body/trim materials, and includes top, top & bottom guided and cage guided valves. In addition they also supply a wide range of desuperheating equipment to satisfy power and steam conditioning applications.

6A-0445 6D-0182

The Quality systems have been approved for the supply of products to meet the requirements of the Pressure Equipment Directive (PED) and compliance modules A,D1,H,B&D have been applied in categories I through IV respectively. The company is committed to compliance with legislation and has an established environment and health and safety policy. An ongoing commitment to customer care is met through the process of continuous improvement and the further development of our systems and processes towards meeting ISO 9001:2000. Valve testing facilities All pressure containing items are hydrostatically tested, seat leakage tested and functionally tested. In addition, gas, packing emission, cryogenic and advanced functional testing can be arranged. Material testing facilities Non-destructive examination by radiography, ultrasonics, magnetic particle and liquid penetrant. Chemical analysis by computer controlled direct reading emission spectrometer. Mechanical testing for tensile properties at ambient and elevated temperatures, bend and hardness testing. Charpy testing at ambient, elevated and sub-zero temperatures. Further technical information can be obtained from our Web site: http://www.weirvalve.com
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CONTENTS
What is a Severe Service Application Summary of Product Range X-Stream Trim How the X-Stream Works Cascade Severe Service Control Valve Trim Severe Service Control Valves Bonnet Forms Characteristics Plug Designs Tables 4 5 6 7-9

10 11 12 13 14 15 - 19

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SEVERE SERVICE CONTROL VALVES

Blakeborough

What is a Severe Service Application?

There are many definitions as to what is and is not considered to be a severe service application, which makes applications difficult to identify for valve manufacturers and customers alike. An application is therefore generally recognised as severe service either through past experience of problems associated with similar applications or because the pressure drop which the valve is required to handle defines the need for a specialist severe service control valve as per the valve manufacturers recommendations. Unfortunately, this second point is highly dependent on the product range offered by a particular manufacturer to the point where an application may be considered severe service by one manufacturer but not by another. However, in an attempt to clarify what is and is not a true severe service application, Weir Valves & Controls found that most applications appear to fall into one of two categories, which are as follows; applications where there is a high pressure drop across the valve (for example in excess of 150 bar) or applications where there are likely to be problems, such as cavitation, high fluid velocities or noise (an example of this would be an application where there may be as little as 40 bar pressure drop across the valve but where the outlet pressure is only slightly above the vapour pressure of the line fluid such that an ordinary valve would be highly likely to cause the onset of cavitation). Severe service applications are considered problematic because of typical problems which are found with the control valves fitted in these services. The valves are more susceptible to problems within these severe environments because of the large amount of potentially destructive energy which must be removed from the fluid flow as it passes through the valve. Typical problems include; high fluid velocities, excessive noise, cavitation, severe erosion, vibration, seat leakage, poor flow control and general valve stability.

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Blakeborough

SEVERE SERVICE CONTROL VALVES

Weir Valves & Controls offer two solutions, where possible the less severe cascade trim which can contain up to 5 sleeves which equates up to 12 turns and is highly economical and the X-Stream trim which is designed to control the most severe of applications. Both of these products can be incorporated into the BV500 and BV990 range of control valves.

Summary of Product Range

X-Stream Size Range Pressure Class Body Configuration Cv Range Valve Characteristic No. of pressure letdown/ velocity control stages Rangeability Leakage Class Temperature Connection Type Bonnet Style Packing Type Plug Design Body Material Cascade

2'' (50 mm) to 30'' (750mm), 1'' (25mm) also available but please consult factory for information ANSI Class 150 to 4500 & PN10 to PN640 (consult factory for equivalent metric and other non standard pressure classes available) Globe & Angle Valve (Globe: BV500 & BV990, Angle: BV501 & BV992) 14us to 500us depending on valve size (consult factory for special designs which require higher or lower Cvs 14us to 1250us depending on valve size (consult factory for special designs which require higher or lower Cvs

Linear, EQ%, Modified Linear, Modified EQ%, Customised. Continuous resistance trim with equivalent of up to 60, specialist design available Up to 100:1 Up to Class VI shut-off -100C (-150F) to 260C (500F) Buttweld, Flanged, (Standard), Socket weld, Screwed (1''only) & Clamped Standard, Normalising, Bellows Seal & Cryogenic PTFE Chevron, Grafoil, LTEP & HTEP Solid, Balanced & Pilot Balanced Carbon Steel; Grade WCB, Stainless Steel; Grade 316/304/347, 1.1/4% Chrome Moly. Steel; Grade WC6, 2.1/4% Chrome Moly. Steel; Grade WC9, Monel, Aluminium Bronze, Hastelloy B/C, Duplex & Super Duplex, other materials available from Weir Foundry - Please consult factory for details. Continuous resistance trim with equivalent of up to 15, specialist design available Up to 60:1

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X-STREAM SEVERE SERVICE CONTROL VALVE TRIM

Blakeborough

A new technologically advanced valve trim for extreme process conditions for Weir Valves and Controls
The new Weir Valves & Controls X-Stream trim has been specifically developed to eliminate the problems of erosion, cavitation and noise on both severe and problematic services. Through its unique flow path design the X-Stream trim is the first of its kind to provide '3D-flow control' within the fluid flow as it passes through the valve. The X-Stream trim is able to ensure superb fluid control and continued reliability through a more accurate and thorough prediction of the fluid flow through the valve. Available in a range of materials the X-Stream has been designed with long term reliable service and ease of maintenance in mind. The disc stack is designed to be separable, increasing ease of on-site maintenance and keeping spares costs to a minimum. Features & Benefits The X-Stream trim is a continuous letdown, cage guided trim design, for both liquid and gas severe service/high pressure applications. X-Stream is designed using the principles of 3D Flow Control to ensure that damaging fluid properties such as high stage pressure gradients, fluid velocity and kinetic energy are kept to a minimum by controlling areas of excessive fluid re-circulation and damaging flow separation in the trim. The unique X-Stream flow path can be designed with an equivalent of up to 50 stages of pressure letdown, when compared to severe service valves fitted with a sharp turn, tortuous path cage design. The X-Stream can be designed to provide a wide variety of dynamic performance characteristics from standard linear, equal percentage to custom designed characteristics. X-Stream flow path contains a natural self cleaning/anti-clogging flow path suitable for dirty/contaminated services resulting in reduced maintenance time and costs. X-Stream trim designed to be incorporated into the BV500 and BV990 range of valves. X-Stream can be retrofit into existing valves supplied by both Blakeborough (BV500 and BV990 range) and other control valve manufacturers.
Pressure drop profile Velocity Profile

The X-Stream can be supplied as either a welded or separable cage disc stack construction depending on customer preference. X-Stream is designed so that all maintenance can be done on site. X-Stream is available in a wide variety of materials. Recommended Applications Turbine Bypass Choke Valves Minimum Pump Flow Recirculation Anti Surge Boiler Feedwater Attemperator Spray Valve Overboard Dump

Figure 1 X-Stream Trim Detail Patent applied for.

The X-Stream can be fitted into valves ranging from 1 (25 mm) to 30 (750mm) with a characteristic rangeability of up to 100:1.

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Blakeborough

HOW THE X-STREAM WORKS - 3D FLOW CONTROL

The advantages of 3D flow control and the X-Stream trim The X-Stream trim is the first in a new and advanced generation of control valve technology, designed to manage the most severe of process environments with continued safe and reliable operation. The X-Stream trim owes its superior performance to an extensive research and development program, which has resulted in the birth of a new design methodology known as 3D Flow Control. This new technique has been used to specify the X-Streams unique design and flow path configuration to ensure that the valve provides optimum performance in service. Controlling a new dimension Severe service applications are notorious for causing problems in the control valves responsible for handling these arduous conditions. Typical problems include poor flow stability, cavitation, erosion (often first seen in the form of seat leakage) and excessive noise and vibration, all of which can have significant effects on the successful performance of the valve. However, although these problems appear varied, in most cases they can be attributed to a poor control of the fluid flow as it passes through the valve, leading to high pressure gradients, high fluid velocities and damaging levels of kinetic energy within the fluid flow. Consequently, a typical severe service control valve will use a number of stages of letdown (either through a labyrinthine style flow path or through a concentric sleeve type cage design) to reduce the pressure drop across each stage, resulting in a reduction of both the fluid velocity and kinetic energy levels. Unfortunately, this simplistic onedimensional approach to the problem does not take into account the three-dimensional formation of the fluid flow as it passes through the valve. Recent research has shown that this can be just as damaging if left uncontrolled. No sharp corners The primary feature of the X-Stream trim is the valve cage, a disc stack cage configuration that incorporates a series of flow paths in which are located an array of staggered cylinders, as shown in figure 1. By forcing the fluid through these tightly packed cylinder arrays, the flow is passed through a labyrinthine tortuous path which is able to dissipate the fluid energy efficiently with limited pressure recovery between stages and without the unnatural movement of the flow around sharp angled corners, such as those found in other severe service trims on the market. This type of unnatural movement has been found to result in numerous problems due to uncontrolled three-dimensional fluid formations within the flow, such as separation and areas of re-circulation see 3D Flow Control Explained, page 8.

Controlling fluid formations As well as providing a method by which the overall design of the valve trim can be improved to more effectively handle the fluid flow, 3D Flow Control also allows the effect of any three-dimensional fluid formations within the flow to be understood and controlled by providing additional and more accurate information which can then be easily incorporated into the standard valve sizing procedures. With the addition of these 3D Flow Control parameters in the standard control valve sizing methodology, each X-Stream trim is designed to maximise performance for each and every set of process conditions supplied. With a pressure drop capability of the equivalent to 50 stages of letdown the X-Stream is capable of safely handling pressure drops of up to 400 bar and, on liquid flows, outlet pressures that are as little as 0.5 bar above the vapour pressure of the line fluid without the onset of cavitation. Application specific materials and custom characteristics The X-Stream is designed to be fitted as a trim option in the Blakeborough BV500 and BV990 range of globe and angle control valves that range in size from 1 (25 mm) to 30 (750 mm). Like all of the valve trim options within this range of control valves, the trim can be designed to provide a variety of dynamic control characteristics ranging from the standard linear, equal percentage and modified equal percentage characteristics to a variety of custom designed characteristics capable of meeting specific customer needs. Depending on the size of the valve the rangeability can be as high as 100:1. In all cases, the trim profiles are designed by advanced computer based programs which are able to optimise the resolution of the valves dynamic performance to match the capabilities of todays highly sensitive control and valve positioning systems. The X-Stream trim can be supplied in a wide variety of materials to cater for every type of process environment and specified as either a welded or separable disc stack arrangement.

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HOW THE X-STREAM WORKS - 3D FLOW CONTROL

Blakeborough

In order for you to see the distinct benefits of the X-Stream trim and the methodology used to we have incorporated this in-depth section which describes the research behind the design.

Unseen velocity increases of up to 50% missed using normal sizing calculations Further investigation revealed that the cause of these three-dimensional formations was, in the main, due to the complex geometry of the valve. For example, sharp, right-angled turns were leading to large areas of re-circulating flow in the outward facing corners. This not only created an area of low static pressure which, on liquid flows, could lead to the early onset of cavitation, but also reduced the hydrodynamic area of the flow path leading to very high fluid velocities. These were exacerbated further as the areas of high fluid velocity were forced to separate off the inward facing corners as shown in figure 2.10. It was found that this large variation in the local fluid velocity level caused the maximum velocity in the flow path to increase by up to approximately 50% of that predicted by traditional one-dimensional control valve sizing methods. As a result of these findings, the X-Stream flow passage has been designed to provide a much more curved flow path; following the natural movement of the fluid flow in order to reduce the presence of these detrimental three-dimensional fluid formations. The close proximity of the cylinders to each other means that the energy is released from the fluid through safely contained interactions and collisions with itself, rather than the internal walls of the passageway which can lead to excessive erosion if left uncontrolled and seriously reduce the lifetime and performance of the trim. As well as reducing the presence of unsteady three-dimensional fluid formations both the local static pressure and the fluid velocity are controlled more evenly through the flow passageway. This results in an overall reduction in the maximum fluid velocity of around 30%, based on the test results conducted during the research programme see figure 2.11.

How the X-Stream Works 3D Flow Control Bringing in the third dimension The X-Stream incorporates a uniquely designed continuous resistance flow passageway to breakdown the total pressure drop into much smaller stages by passing the flow through a tortuous array of tightly packed cylinders. This increases the resistance to the flow provided by the passageway and therefore the valve trim, thus reducing the fluid velocity. However, unlike other severe service control valves on the market, the X-Stream is designed and sized using the methodology of 3D Flow Control. The X-Streams unique continuous resistance flow passage arrangement is the result of a 5 year research and development program and has been designed using modern computational and experimental analysis equipment. These advanced techniques enable detailed understanding of how the complex, tortuous flow paths used in other severe service trims were able to handle the high pressure drops across the trim. It became clear that the fluid flow through the passageways in the valve trim were subject to high levels of turbulence and a number of complex three-dimensional fluid formations such as areas of re-circulating flow, vortices and jet formations. The presence of these disturbances was leading to a wide variation in both the local static pressure and velocity profiles through the flow path see below.

2.11 Velocity profile through the X-Stream.

2.10 Velocity profile through a typical severe service trim flow path.

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HOW THE X-STREAM WORKS - 3D FLOW CONTROL

CFD identifies cavitation potential where standard methodology fails Its unique flow passage design also provides the XStream trim with its self-cleaning capabilities, by allowing small particles to pass through the flow without obstruction, preventing particle build-up which can eventually lead to the flow paths becoming blocked and inevitably valve failure. The valve trim is also designed so that it can be easily maintained on site and, where possible, a separable disc stack gives maximum flexibility. In addition to providing a superior valve trim design, the XStream is able to go one step further by applying the methodology of 3D Flow Control to the sizing and selection of the valve. Whilst the X-Stream has a significantly improved flow path which is better able to control the fluid velocity, static pressure and prevent the onset of cavitation there are still three-dimensional formations within the fluid flow which can effect the performance of the valve. Whilst these three-dimensional formations exist, accurate fluid velocities are almost impossible to predict using the oversimplified one-dimensional theory which forms the basis of most existing control valve sizing methods. This also means that relating properties such as the local static pressure levels, temperature and fluid density used to predict the presence of cavitation or high levels of noise will be subject to some degree of inaccuracy. Some manufacturers will claim that whilst this is true, the level of this inaccuracy is so small that it does not warrant further complication of existing sizing methods. However, although this may be acceptable for simple control valves, such as those fitted with single-stage trim devices like the Blakeborough multi-flow or contour trim. For highly complex severe service trims the research conducted by WVC UK indicated that this is not a safe assumption.

The investigation used two prediction techniques to determine the onset of cavitation within an XStream trim: the first using computational fluid dynamics (CFD) to predict the points at which the local static pressure fell below the minimum static pressure see figure 2.12 - and the second was based on the same principles used in existing onedimensional sizing techniques. The results were then compared with the cavitation damage on an actual valve trim under the same conditions. Under the one-dimensional prediction technique an average level of static pressure was assumed which, when compared with the fluid vapour pressure, was found to be higher suggesting no cavitation would occur. Using the three-dimensional technique (CFD) suggested local areas of cavitation attached to the sides of the cylinders, comparing very well with the actual damage seen on the prototype trim see figure 2.13. Whilst it is not practical to conduct a CFD analysis on every severe service control valve in order for it to be correctly sized, this evidence highlights the sources of error within existing one-dimensional control valve sizing theory and the importance of understanding how the individual geometrical aspects of the valve can affect performance: for example, changing the diameter or spacing of the holes in the concentric sleeve trim.

2.13 Comparison of predicted damage to actual damage.

Based on in-depth study of the of the X-Stream trim, Weir Valves & Controls has created a new sizing method in accordance with current IEC and ISA standard sizing practices, which takes into account the geometrical aspects of the valve that may affect its performance. Using this information, the valve is then sized based on the maximum/minimum fluid flow conditions, such as maximum velocity and minimum static pressure. The X-Stream is just one of the products in the Weir Valves & Controls Blakeborough range of control valves, a name synonymous with quality from a UK based manufacturer with over 50 years experience in providing the customer with technologically advanced solutions. In addition, the Blakeborough product range includes an extensive choice of control valve and desuperheating equipment with expert application knowledge in the power, processing and oil and gas sectors.

2.12 Example of cavitation damage prediction using CFD.

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CASCADE SEVERE SERVICE CONTROL VALVE TRIM

Blakeborough

Cascade (CS) The Cascade valve trim is a further advancement over the standard Multi-flow valve cage. It is used in control applications where high noise levels or cavitation would be predicted, with a standard trim design. Noise, flow erosion and/or vibration can result in a high pressure drop/ratio application if attention to controlling the pressure drop is not considered. The cascade trim has been specifically designed to eliminate these problems at source by controlling the pressure drop through a number of discrete stages of let-down. The Cascade cage is manufactured to close tolerances and consists of a series of sleeves. The number of sleeves (stages of let-down) required depends upon the amount of treatment necessary for the particular application. Each successive sleeve, has a number of radial holes, and a carefully calculated increase in flow area to ensure correct apportionment of the pressure drop. Thus, the small radial jets pass through a tortuous flow path resulting in high frictional and impingement losses. At the same time the impingement of the jets onto the outer radially drilled sleeves control the shock wave formation which has a major influence on overall noise reduction in gas/vapour applications. Variable Stage Cascade (VS) Is available when multiple stages of pressure letdown are required at low valve openings. This design particularly suits applications where there is a high-pressure drop at low flows, and a reduced pressure drop at normal to maximum flow-rates. The design philosophy of the Cascade and MultiFlow Trims designs is combined within this trim.

Body Protection Unit This design option is utilised on flashing liquid, multi-phase fluids, and on contaminated gas/vapour flows. The unit is designed to prevent erosive outlet flow, from the valve seat, directly impinging onto the pressure containing body walls. It is manufactured from hardened or hard-faced material to reduce erosion rates. The design breaks the erosive fluid flow into small jets and directs the bulk of the flow towards the valve outlet.

Body Protection Unit

Variable Stage Cascade

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SEVERE SERVICE CONTROL VALVES

Versatility Blakeborough offer a wide choice of options to meet most system requirements, eliminating or greatly reducing the multiplicity of valve designs that would otherwise be required. This flexible range of valves offers an extensive selection of trim designs, materials and sizes, and is therefore able to meet the ever increasing demands of modern day plant. All parts are interchangeable between globe and angle style valves in a given size and pressure rating. Parts substitution, internal inspection and maintenance are effected with minimum trouble, the essential working components being removable while the body remains undisturbed in the pipeline. Simple, low cost, in line maintenance Comprehensive interchangeable parts systems High-stability plug guiding High flow capacity Main design standards ASME B16.34 Valve Flanged, Threaded & Welded Ends ANSI FCI 70-2 Control Valve Seat Leakage ASME B16.25 Butt Weld Ends ASME B16.5 Pipe Flanges & Flange Fittings NACE MR-01-75 Valve Materials (option) BS1560 Circular Flanges for Pipes, Valves & Fittings BS4504 Circular Flanges for Pipes, Valves & Fittings Features Pressure Ratings ANSI Class 150lb to 600lb (BV500 Series) ANSI Class 900lb to 4500lb (BV990 Series) Equivalent metric pressure ratings Body A choice of globe or angle patterns available BV500 & BV990 Globe body BV501 & BV992 Angle body

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SEVERE SERVICE CONTROL VALVES

Blakeborough

Bonnet forms Standard For applications where the temperature of the controlled fluid is between -18C (0F) and 232C (450F). May be used with graphite packing up to 315C (600F). Although modern packagings are suitable for much higher temperatures it is recommended that the normalising bonnet be fitted in cases where the temperatures exceed the above values to accommodate lagging of the control valve body. Normalising For protection of the gland packing at temperatures above 232C (450F) and below -18C (0F) down to -100C (-150F) The bonnet is designed with fins which dissipate the heat from process fluid and help protect the packings and actuator assembly from high temperatures. In addition the normalising bonnet is longer than the standard plain bonnet so that the valve can easily be lagged without interference with the actuator. Bellows Seal A positive leakproof stem seal for cases where gland leakage cannot be permitted. The standard bellows material is 321 stainless steel, although many other materials are available on request. The design consists of a welded flexible steel bellows which is clamped in an extended bonnet/bonnet hood. This effectively cuts out any possible leakage path around the plug stem and therefore prevents emissions from the valve packings. Packings are fitted in these valves but only act as a backup to the bellows. Cryogenic Used for temperatures below -100C (-150F). The bonnet designed with a long necked section which distances the packing away from the process fluid. The necked section is designed with a minimum wall section to minimise heat transfer. Cold box extension/cryogenic bonnets are also available. Packing Packings are selected based on fluid temperature and fluid type. The most common packing system materials are PTFE for low temperature and graphite for high temperature. For hydrocarbons service and where emission levels need to be controlled there are two further types of packings available. These incorporate specially selected materials and live loading to both minimise emissions and extend packing life allowing for cyclic operation. These packings are referred to as LTEP and HTEP. Packings have been tested to prove emission levels of less than 500 parts per million over 50,000 cycles and under thermal cycling conditions.

PTFE Chevron is used for applications where the temperature is between cryogenic to 232C (450F) Grafoil is used on high temperature applications where the temperature exceeds 232C (450F) LTEP low emission packing, temperatures below 260C (500F) HTEP low emission packing, temperatures above 260C (500F) Other packing types can be accommodated as required.
PTFE Chevron

Grafoil

Standard

Normalising

Bellows Seal

Cryogenic

Silencers Silencers/Dynamic Attenuator This equipment is used on gas/vapour services to control fluid velocity and to produce dynamic attenuation. Each silencer is designed for its specific application and is considered in conjunction with the selection of the upstream control valve/trim. In selecting the silencer design all operating conditions are considered to ensure acceptable performance.

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SEVERE SERVICE CONTROL VALVES

100 90

Characteristics
NIN

80 70 60 50

Linear
U
R

ED
RT

LI N

20 10 0 0 10 20 30 40 50

EQ

L UA

PE

RC

60 70

TA

30

80 90 100

40

EA

% FLOWRATE

This characteristic provides a flow rate which is directly proportional to the valve lift. The proportional relationship produces a characteristic with a constant slope, so that with constant pressure drop the valve gain will be the same at all flows. The linear valve plug is commonly specified for liquid level control and for flow control applications requiring constant gain. Equal Percentage Equal increments of valve lift produce equal percentage changes in the fluid flow. The change in flow rate is always proportional to the flow rate just before the change in plug position is made. The equal percentage characteristic is generally used on pressure control applications, and on other applications where a large percentage of pressure drop is normally absorbed by the system itself. Valves with this characteristic should also be considered where highly varying pressure drop conditions occur or high rangeability is required. Quick Opening This provides for maximum change in flow rate at low valve lifts with a fairly linear relationship. Additional increases in valve lift give sharply reduced changes in flow rate, when the valve plug nears the wide open position, the change in flow rate approaches zero. Intermediate Other intermediate or special characteristics are available on request to meet specific control requirements.

CK

OPE

Q UI

TO

VALVE LIFT % OF FULL LIFT

P O

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SEVERE SERVICE CONTROL VALVES

Blakeborough

Plug designs Balanced The balanced plug design is utilised to greatly reduce fluid forces acting on the valve plug allowing economical actuation and stable control. The cylindrical plug head is drilled with balancing ports to admit pressure above the plug head. The annular leakage flow between the valve plug and cage is minimised by a sealing ring retained within a plug groove. The standard sealing rings are carbon graphite which give Class III leakage. Alternatively a U seal can be fitted to give either Class IV or Class V leakage dependent on seating load applied by the actuator. Solid (Unbalanced) The design is used on relatively low-pressure drop and/or on-off applications. It generally requires the use of much larger actuators than would be required on the balanced plug design and in all but small valve sizes is not suited to control applications. Pilot Balanced Trim The pilot balanced plug design incorporates two plugs, the main larger diameter plug used for control and the smaller pilot situated inside the main plug significantly reduces fluid forces acting on the main plug. This design produces a high integrity metal temperature where a resilient seal would be unsuitable. Opening of the valve is by the pilot plug, which lifts from its seat prior to the main plug head. This produces a flow passage to equalise the pressure above and below the valve plug, thereby significantly reducing the fluid forces acting on the valve plug. in the closed position the inlet pressure is admitted above the plug to produce a high downward seat load and the only leakage path is across metal to metal seating. Flash-cone This plug design is specified on applications requiring a very high rangeability. At low openings the conical plug nose fits inside a matching conical seat. The plug nose has a number of circumferential grooves, which produce a staging of the pressure drop as the flow passes between the small annular passage between the plug and the valve seat. In addition to the increased rangeability this trim also allows the valve to handle higher-pressure drops at low valve openings than can be adequately handled by a standard plug design.

Soft seat Is specified on applications where it is desirable to have a maximum closure on the control valve. The soft seat design consists of a resilient seal ring clamped into the plug by a face ring. When the soft seal contacts the valve seat, a lip on the seat bites into the face of the seal and effectively prevents leakage through the seat. The soft seat design can be specified in both balanced and un-balanced designs.

Seal Rings On balanced design valves the valve plug is designed to incorporate a seal ring which prevents leakage around the periphery of the valve plug. Depending upon the desired leakage and temperature through the valve a variety of seal rings are specified.

Carbon Ring

Triple Seal Ring

U Seal

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SEVERE SERVICE CONTROL VALVES

Table 1 Materials of construction

Cage 420 ST.ST. Hardened 420 ST.ST. Hardened 316 ST.ST./ 17-4PH ST.ST. 420 ST.ST. Hardened Monel K500 Hastelloy C Duplex Ceramic/420 ST.ST. Inconel 625 17-4PH ST.ST. + TC Duplex + TC Plug 17-4PH ST.ST. Hardened 316 ST.ST. with Stellite face & Guide 316 ST.ST. with Chrome Plated Guide Diameter 17-4PH ST.ST. Hardened with PTFE Face Monel 400 Hastelloy C Duplex 316 ST.ST. + Ceramic Inconel 625 17-4PH ST.ST. + TC Duplex + TC Plug Stem 316 ST.ST./ 17.4 PH Seat Integral with Cage/ 316 ST.ST./ 316 + Stellite Service -35C to 399C -30F to 750F 400C to 565C 750F to 1050F NACE MR-01-75 -35C to 232C -30F to 450F -35C to 232C -30F to 450F -35C to 500C -30F to 932F -

316 ST.ST. Monel 400/ Monel K500 Hastelloy C Duplex 316 ST.ST. Inconel 625 316 ST.ST. Duplex Integral with Cage/ Monel K500 Integral with Cage/Hastelloy C Integral with Cage/Duplex 316 ST.ST. + Ceramic Integral with Cage/ Inconel 625 17-4PH ST.ST. + TC Duplex + TC

*options for Stellite face or full Stellite available for most materials. TC = Tungsten Carbide

Table 2 Leakage glass

Leakage Class Class 111 Class IV & V Class IV & V Class IV & V Class IV Class V & MSS-SP-61 Class VI Class III, IV & V Seal Ring Material Carbon Graphite Carbon PTFE U Seal High temp U Seal Virgin PTFE USeal Carbon Triple Seal Pilot Balanced Soft Face Seat None (un-balanced) Temperature -35C (-30F) to 565C (1050F) -35C (-30F) to 260C (500F) 260C (500F) to 350C (660F) Cryogenic to -35C (-30F) 350C (660F) to 565C (1050F) -35C (-30F) to 565C (1050F) -35C (-30F) to 232C (450F) Cryogenic to 565C (1050F)

Table 3 Recommended limiting velocities

Metric Units Body Size (MM) 40, 50 80, 100 150, 200, 250, 300 350, 400, 450, 500 600 Liquid (M/S) 13.5 13.5 13.5 12 8.5 Steam or Gas (M/S) 150 150 150 130 120 Body Size (IN) 1 12, 2 3, 4 6, 8, 10, 12 14, 16, 18, 20 24 US Units Liquid (FT/S) 44 44 44 39 28 Steam or Gas (Ft/S) 490 490 490 425 390

Note: Maximum outlet velocity (steam or gas) = 0.65 x sonic

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SEVERE SERVICE CONTROL VALVES

Blakeborough

M L L

N F/2 F
BV500

F/2

Table 4 BV500 series valves dimensions

Valve Size 1 12" 40mm Up to ANSI 300 Class RF and BS4504 Up to ANSI 300 Class RTJ Class 300 Butt Weld 9 14 235 9 34 248 2" 50mm 10 12 267 11 18 283 11 14 286 11 14 286 11 38 289 5 1316 148 4 78 124 10 1116 272 9 34 248 13 916 344 12 58 320 17 14 438 16 516 414 3 58 92 1 18 28.5 2 18 54 3" 80mm 12 12 317 13 18 333 13 14 337 13 14 337 13 38 340 7 916 185 5 12 140 11 34 298 9 1516 253 16 1516 430 15 58 397 17 1316 455 16 916 421 4 1116 119 1 12 38 2 1316 71 4" 6" 8" 10" 12" 14" 16"

BV501

BV500 Extension Bonnet

18"

20"

24"

30"

100mm 150mm 200mm 250mm 300mm 350mm 400mm 450mm 500mm 600mm 750mm 14 12 368 15 18 384 15 12 394 15 12 394 15 58 397 7 58 193 6 516 160 12 116 306 10 34 273 161516 430 15 58 397 17 1316 455 16 916 421 5 516 135 1 12 38 2 1316 71 18 58 473 19 14 489 20 508 20 508 20 18 511 9 1516 252 7 716 189 14 716 368 12 305 22 916 572 20 116 509 21 58 550 20 18 511 6 34 172 2 14 57 3 916 90 22 38 568 23 584 24 610 24 610 24 18 613 13 316 335 9 516 237 18 457 14 18 359 30 116 763 26 316 665 25 38 645 21 12 546 8 12 216 3 12 89 3 916 90 10 58 270 12 18 308 16 406 7 178 5 127 16 406 7 178 5 127 18 58 473 10 254 5 127 18 58 473 10 254 5 127 21 38 543 12 305 5 127 CF CF CF 35 78 910 CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF 32 815 CF 33 916 853 CF CF CF CF CF CF CF CF CF CF CF CF CF 25 34 655 CF 28 12 724 CF 41 58 1057 CF 41 58 1057 CF 52 1321 CF 52 1321 CF 59 1499 CF CF CF 28 14 718 28 78 733 30 762 30 762 30 18 765 18 1116 475 CF 30 12 775 31 18 791 30 12 775 32 14 820 32 38 823 20 316 513 CF 41 58 1057 42 14 1073 41 58 1057 43 58 1108 43 34 1111 23 38 721 CF 41 58 1057 42 14 1073 41 58 1057 43 58 1108 43 34 1111 23 38 721 CF 47 1194 47 58 1210 47 1194 49 14 1251 49 38 1254 37 78 963 CF 54 1372 54 58 1388 54 1372 60 1524 60 18 1527 37 78 963 CF 60 1524 60 58 1540 60 1524 63 1600 63 18 1603 43 78 1114 CF CF 66 1676 66 58 1692 66 1676 70 1778 70 18 1781 CF

9 78 251

BS, PN64, PN100, ANSI 600 Class RF Flanged & Butt Weld ANSI 600 Class RTJ

9 78 251 9 78 251

Plain Bonnet (L)

5 1316 148

Plain Bonnet (M)

4 78 124

Norm Bonnet (L)

10 1116 272

Norm Bonnet (M)

9 34 248

Bellows Bonnet (L)

13 916 344

Bellows Bonnet (M)

12 58 320

Extension Bonnet (L)

17 14 438

Extension Bonnet (M)

16 516 414

3 12 89

Standard Travel (Also refer to Table 8) Bonnet Mount Dia

1 18 28.5 2 18 54

3 12min 3 12min 89 5 127 89 5 127

Extended Travels for Cascade Trim Valves Extended travel (Refer Table 9) Bonnet Mount Dia 1 12 38 2 1316 71 Plain L 8 18 207 Norm L 12 34 324 1 12 38 2 1316 71 8 18 207 12 34 324 2 14 57 3 916 90 10 916 268 16 400 2 14 57 3 916 90 9 78 251 15 1316 386 3 12 89 3 916 90 13 516 338 18 1316 478 6 152 5 127 18 58 473 24 600 6 152 5 127 22 555 30 765 7 178 5 127 26 650 34 12 877 CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF

RF = Raised Face. RTJ = Ring Type Joint. Face-to-Face and Face to Centre Line Dimensions are generally in accordance with ISA 5.75.03. CF = Consult Factory.

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Table 5 BV990 series valves dimensions

VALVE SIZE 1 12 2 3 4 6 8 10 12 14 16 18 20 24 30

40mm 50mm 80mm 100mm 150mm 200mm 250mm 300mm 350mm 400mm 450mm 500mm 600mm 750mm RATINGS UP TO AND INCLUDING ANSI CLASS 1500lb ANSI 900 RF & PN160 ANSI 900 RTJ ANSI 1500 RF & PN250 ANSI 1500 RTJ ANSI 900 & 1500 PN160 & PN250 Butt Weld Plain Bonnet Norm Bonnet 313 N 86 Standard Travels Bonnet Mount Dia ANSI CLASS 2000lb ANSI 2000 Butt Weld Plain Bonnet Norm Bonnet N Travel Bonnet Mount Dia ANSI CLASS 2500lb ANSI 2500 Butt Weld Plain Bonnet Norm Bonnet N Travel Bonnet Mount Dia 12 305 12 305 13 14 337 13 38 340 13 14 337 13 38 340 13 14 337 8 12 215 12 78 355 3 34 126 1 18 28.6 2 18 54 14 14 368 8 916 217 13 916 344 4 116 103 1 18 28.6 2 18 54 16 14 413 10 14 260 14 78 377 4 38 110 1 18 28.6 2 1316 71 15 12 394 15 58 397 16 14 413 16 38 416 16 14 413 9 38 238 14 406 5 149 1 12 38 2 1316 71 20 508 9 78 251 15 18 385 5 128 1 12 38 2 1316 71 21 12 546 11 58 296 16 58 422 5 128 1 12 38 3 916 90 18 12 470 18 58 473 19 14 489 19 38 492 19 14 489 11 34 298 16 415 5 78 188 2 14 57 3 916 90 24 610 12 18 309 16 58 422 6 116 154 2 14 57 3 916 90 25 58 650 15 381 19 78 504 7 177 2 14 57 3 916 90 21 78 556 22 559 24 610 24 14 616 24 610 11 78 302 16 516 695 7 38 286 2 14 57 3 916 90 32 813 13 34 350 20 507 9 14 235 2 14 57 3 916 90 35 716 900 20 14 514 26 38 669 9 38 238 2 14 57 3 916 90 36 34 934 36 78 937 39 990 39 38 1001 39 38 1001 19 58 498 27 v 750 11 14 315 3 12 89 3 916 90 39 990 19 58 499 27 38 696 11 14 286 3 12 89 3 916 90 45 14 1150 25 12 649 45 14 846 12 38 315 3 12 89 5 127 3 12 89 5 127 5 127 5 127 5 127 5 127 5 127 5 127 5 127 REFER TO TRIM SELECTION CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF 36 914 36 18 918 45 1142 45 38 1153 45 1142 23 34 602 29 12 800 12 38 330 3 12 89 5 127 44 1516 1142 22 34 603 31 12 800 13 38 339 3 12 89 5 127 55 18 1400 CF 5 127 63 1600 CF 5 127 71 1803 CF CF CF CF CF CF 5 127 CF 5 127 CF 5 127 CF 5 127 CF 5 127 CF 5 127 52 1321 26 14 667 34 18 867 15 58 397 REFER TO TRIM SELECTION CF CF CF CF CF CF CF CF CF CF CF CF 5 127 CF 5 127 CF 5 127 CF 5 127 68 1727 33 78 859 CF CF CF CF CF 5 127 CF 5 127 CF 44 12 1130 44 12 1130 45 18 1146 45 18 1146 45 18 1146 26 34 680 31 12 902 13 342 56 1422 56 1422 56 1422 56 1422 56 1422 28 34 730 35 12 902 13 12 342 56 1422 56 1422 56 1422 56 1422 56 1422 28 34 730 35 12 1105 13 12 451 68 1727 68 1727 68 1727 68 1727 68 1727 37 940 43 12 1250 17 34 500 68 12 1740 68 12 1740 68 12 1740 68 12 1740 68 12 1740 41 12 1054 49 14 1178 19 58 582 22 78 CF 46 38 CF CF CF CF CF CF CF CF CF CF CF CF CF

12 305 12 305 12 305 7 78

200 12 516 327 3 38 95 1 18 28.6 2 18 54 12 305 7 78 200 12 516 313 3 38 86 1 18 28.6 2 18 54 14 18 359 8 78 225 14 355 4 100 1 18 28.6 2 1316 71

REFER TO TRIM SELECTION

CF = Consult Factory Consult factory for ANSI Class 4500lb Rated Valves

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M L N F/2

BV990

BV992

F/2

Table 6 BV992 series valves dimensions

VALVE SIZE 1 12 2 3 4 6 8 10 12 14 16 18 20 24 30

40mm 50mm 80mm 100mm 150mm 200mm 250mm 300mm 350mm 400mm 450mm 500mm 600mm 750mm RATINGS UP TO AND INCLUDING ANSI CLASS 1500lb ANSI 900 RF & PN160 ANSI 900 RTJ ANSI 1500 RF & PN250 ANSI 1500 RTJ ANSI 900 & 1500 PN160 & PN250 Butt Weld Plain Bonnet Norm Bonnet Standard Travels Bonnet Mount Dia ANSI CLASS 2000lb ANSI 2000 Butt Weld Plain Bonnet Norm Bonnet Travel Bonnet Mount Dia ANSI CLASS 2500lb ANSI 2500 Butt Weld Plain Bonnet Norm Bonnet Travel Bonnet Mount Dia 6 152 6 152 7 178 7 116 179 7 178 7 116 179 6 58 168 7 178 11 716 290 1 18 28.6 2 18 54 7 14 184 7 178 12 306 1 18 28.6 2 18 54 8 18 207 CF CF 1 18 28.6 2 1316 71 8 18 206 8 1316 208 8 12 216 8 916 218 8 12 216 7 716 188 12 304 1 12 38 2 1316 71 10 254 7 1316 199 13 18 333 1 12 38 2 1316 71 10 34 273 CF CF 1 12 38 3 916 90 9 14 235 9 516 237 9 58 244 9 1116 246 9 58 244 9 116 230 13 38 339 2 14 57 3 916 90 12 305 9 716 239 13 78 352 2 14 57 3 916 90 12 1316 325 CF CF 2 14 57 3 916 90 2 14 57 3 916 90 17 34 450 CF CF 2 14 57 3 916 90 3 12 89 3 916 90 22 58 575 CF CF 3 12 89 5 127 3 12 89 5 127 27 916 700 CF CF 3 12 89 5 127 5 127 5 127 5 127 5 127 5 127 5 127 5 127 5 127 31 12 800 CF CF CF CF CF CF CF CF CF CF CF CF CF CF 5 127 CF 5 127 CF 5 127 CF 5 127 CF 5 127 CF 5 127 CF REFER TO TRIM SELECTION 2 14 57 3 916 90 16 407 12 316 310 CF 3 12 89 3 916 90 19 14 495 16 14 413 CF CF CF CF CF CF CF CF CF 3 12 89 5 127 22 14 565 CF 5 127 24 34 629 CF CF CF CF CF CF CF 5 127 CF 5 127 CF 5 127 CF 5 127 CF 5 127 CF 5 127 CF REFER TO TRIM SELECTION CF CF CF CF CF CF CF CF CF CF 12 1316 310 12 14 311 13 14 337 13516 338 13 14 337 CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF

F 2

6 152 6 152 6 152 6 78

175 11 38 288 1 18 28.6 2 18 54

F 2 M

6 152 6 78 175 11 38 288 1 18 28.6 2 18 54

F 2 M

6 78 175 CF CF 1 18 28.6 2 1316 71

REFER TO TRIM SELECTION

CF = Consult Factory Consult factory for ANSI Class 4500lb Rated Valves

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Table 7 Approximate weight Kg

SIZE BONNET STYLE UP TO 300LB (PN 40) FLG 40mm 1 12 Plain Norm Bellow Plain Norm Bellow Plain Norm Bellow Plain Norm Bellow Plain Norm Bellow Plain Norm Bellow Plain Norm Bellow Plain Norm Bellow Plain Norm Bellow Plain Norm Bellow Plain Norm Bellow 20 23 30 21 24 31 58 62 76 67 72 96 148 153 185 230 235 282 400 452 495 540 605 640 1571 1602 1740 CF CF CF CF CF CF BW 18 21 28 18 21 28 30 34 48 52 58 81 108 114 145 316 323 368 510 588 612 495 562 598 1440 1471 1609 CF CF CF CF CF CF 600LB RATING (PN 100) FLG 22 25 32 30 33 40 60 64 78 88 94 117 179 185 216 331 338 383 545 630 690 597 679 739 1709 1752 CF 3370 3440 CF 5010 5090 CF BW 18 21 28 18 21 28 30 34 48 52 58 81 108 114 145 316 323 368 510 588 612 548 610 689 1610 1652 CF CF CF CF CF CF CF 900 & 1500LB RATING (PN150 & PN250) FLG 24 29 N/A 42 47 N/A 61 71 N/A 205 215 N/A 320 340 N/A 702 735 N/A 1300 1367 N/A 1800 1900 N/A 2200 2290 N/A CF CF N/A CF CF CF BW 20 25 N/A 34 39 N/A 50 60 N/A 177 187 N/A 279 299 N/A 655 685 N/A 1198 1265 N/A 1655 1755 N/A CF CF N/A CF CF N/A CF CF CF 2000LB RATING (PN 330) FLG N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A CF CF CF BW 24 29 N/A 42 47 N/A 57 67 N/A 197 207 N/A 430 480 N/A 805 860 N/A 1670 1789 N/A 2098 2199 N/A CF CF N/A CF CF N/A CF CF CF 2500LB RATING (PN 420) FLG 32 37 N/A 51 56 N/A 84 93 N/A 292 310 N/A 577 622 N/A 1150 1208 N/A CF CF N/A CF CF N/A CF CF N/A CF CF N/A CF CF CF BW 27 32 N/A 43 48 N/A 70 79 N/A 242 260 N/A 495 540 N/A 999 1057 N/A CF CF N/A CF CF N/A CF CF N/A CF CF N/A CF CF CF

50mm 2

80mm 3

100mm 4

150mm 6

200mm 8

250mm 10

300mm 12

400mm 16

500mm 20

600mm 24

Table 8 End connection details for butt weld end valves (mm)
VALVE SIZE BV500 ALL RATINGS BV990 UP TO & INCLUDING BV990 2000LB RATING 1500LB (PN 250) (PN 330) ID 38 38 65 85 140 190 OD 89 85 115 155 205 310 ID 38 38 75 85 125 200 255 325 OD 89 95 130 145 235 340 390 515 BV990 2500LB RATING (PN 420) ID 38 38 75 90 130 195 255 OD 89 95 145 185 265 350 450

ID 40mm (1 12) 50mm (2) 80mm (3) 100mm (4) 150mm (6) 200mm (8) 250mm (10) 300mm (12) 400mm (16) 500mm (20) 600mm (24) 750mm (30) 20 38 65 90 145 185 250 300 370

OD 70 80 105 145 200 255 315 370 460

CF = Consult factory

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